AQUATO K-Pilot 8.3 User manual

Version 01.06.2011
Operating instructions
aquato
K-Pilot Control

These operating instructions are available for you to
download in DIN A4 format as a PDF file on our home
page www.aquato.de in the “Downloads” section.

Table of contents
1 General description 4
2 Safety instructions 4
2.1 Identification of instructions in the operating instructions 4
2.2 Please note 4
3 Connections 6
3.1 Mains connection 6
3.2 7-pole plug 6
3.2.1 Submerged aerator 6
3.2.2 Filling/sludge pump 6
3.2.3 Clear water pump 6
3.2.4 Float switch 6
3.3 Floating contact 6
4 Function 7
4.1 Operation and displays 7
4.2 Commissioning 8
4.3 Main display 8
5 Menu 9
5.1 Menu structure 9
5.2 Runtime display 10
5.3 Service menu 10
5.3.1 System test / test mode 10
5.3.2 Manual mode 11
5.3.3 Select plant size 11
5.3.4 Phosphate elimination 11
5.4 Basic settings 12
5.4.1 Date and time 12
5.4.2 Alarm buzzer 12
5.4.3 Display errors (log book) 12
5.4.4 Language 12
5.4.5 LCD contrast 13
5.4.6 Clear alarm 13
5.5 System menus for individual settings 13
5.5.1 Aeration 13
5.5.2 Denitrification 13
5.5.3 Parameters 14
5.5.4 Current monitor 14
6 Malfunctions / Alarm 14
7 Power failure alarm 15
8 Assembly instructions 15
9 Technical data 16
10 Default settings 16
11 Switching times 17
12 Error messages 17
13 Notes 18
14 Manufacturer certification 19

2.1. Identification of instructions in the operating instructions
The safety instructions included in this doc. which could endanger persons if they are not observed
are identified with the general hazard symbol.
Electrical voltage warnings are specially indicated with the following symbol.
2.2 Please note
Continued on page 5
These operating instructions apply exclusively to the switching device (control) and contain
important instructions and warnings.
The operating instructions must be read prior to the assembly and commissioning by the
fitter and the responsible operator of the plant and observed.
Not only the general safety instructions listed under the main entry “Safety instructions” need
to be observed, but rather all the special safety instructions included under the following main
points.
These operating instructions do not take all design individualities and versions into account,
nor all the possible eventualities and results which might arise during assembly, operation
and maintenance.
Prerequisite for the assembly and handling of the switching device is the deployment of specially trained
personnel (see EN 50 110-1). Should you require information and instructions that you cannot find in
these operating instructions, please do not hesitate to consult the manufacturer.
The manufacturer and supplier of the switching device accepts no responsibility in cases where the
instructions are not observed.
4
1 General description
2 Safety instructions
The switching device controls a submerged aerator, a filling- / sludge pump and a clear water
outflow pump of a small wastewater treatment plant in accordance with the SBR principle in cycles.
When in operation the currents of the motors are monitored in order to identify plant errors as
much as possible. With the K-Pilot 8.4 it is also possible to connect a unit for dosing a precipitant
for phosphate elimination.

These operating instructions include important information which must be observed when setting-up,
commissoning and operating the plant. These operating instructions must be kept readily available
at the place where the plant is employed.
The control may only be connected and maintained by a
suitably qualified specialist.
PPrior to commissioning and turning on the mains it must be ensured that
- the device and the power supply cords are free from visible damage
- in particular the mains connections and the motor connections are connected up properly
- all connections have been performed correctly and expertly
- the laying and conducting of all cables and cords complies with the applicable regulations
- the device is correctly closed
- the plant is expertly fused
The respectively applicable regulations (EN, VDE, ...) And the regulations of the local energy
supplier must be observed.
If a fuse is defective, it must only be replaced with a microfuse of the following type:
microfuse, time-lag, type 3,15 A , 5 x 20 mm in accordance with EN 60127-2/III with a maximum
power loss of 1,5 W. This fuse is also inserted in the factory.
Note:
A stronger fuse can be employed for larger plants (max. 6,3 AT).
Fuses must always be replaced with a fuse of equal strength.
Prior to replacing the fuse, ensure that the device is completely turned off and disconnected from
the electricity supply (unplug).
Ensure device is turned off and disconnected from the
power supply before opening it (Unplug!).
Caution:
- Sensitive components
- Risk internal cabling can become loose
- live parts
5
2 Safety instructions
Always unplug before working on pumps and aerator!

3.3 Floating contact
The floating contact can be used to connect an additional warning
lamp / flashing light.
This can be supplied with electricity via the control or over another
independent / external cable.
In the case of an alarm, the relay closes the connection between
clips 11 and 12 and opens the connection between 11 and 14.
Continued on page 7
3.1 Mains connection
The plant is connected to the mains by means of the supplied power cable (approx. 1,5 m long) with
Shock-proof plug (clips L1, N, PE). Fuse protection on line side: max. 1 x 16 AG.
3.2 7 - pole plug
The following inputs and outputs are routed through a 7 - pole plug on the underside of the device.
3.2.1 Submerged aerator
The submerged aerator is connected via the 7 - pole plug on the underside of the housing.
3.2.2 Filling / sludge pump
The pump is connected via the 7 - pole plug on the underside of the housing.
3.2.3 Clear water pump
The clear water pump is connected via the 7 - pole plug on the underside of the housing.
3.2.4 Float switch
The float switch is connected via the 7 - pole plug on the underside of the housing.
Control voltage: 230 V~ approx. 5 mA, switching between input and N.
Cutting through the control cable results in loss of warranty!
6
3 Connections
Connector assignment of 7 –pole plug (as delivered)
No.Cable colour Function
1Black Submerged aerator
2Brown Filling / sludge pump
3Purple Clear water outflow
4Blue N (neutral wire)
5Orange Switch contact float switch
6White N (float switch)
7Green / Yellow Earth wire

4 Function
7
If you want the warning light / flashing light to illuminate / flash in the event of an error, it should
be connected via contacts 11 and 12 (see diagram).
For continuous illumination, the connection between 11 and 14 should be chosen.
3 Connections
4.1 Operation and displays
The control has a graphic LCD - display mit 128 x 64 pixels.
The displays appear in plain text.
It is operated via three buttons and two LEDs.
The green LED is illuminated continuously if a motor is on.
In the event of an malfunction / error, the red LED flashes. I
If both the green and red LEDs are illuminated continuously, the unit is in the
initialisation phase.
During normal operation, the green LED flashes and in addition a flashing triangle can be seen in
the lower right handcorner of the LCD display.
Each menu is composed of a row of displays on the LDC display.
You can change from menu to menu using the arrow keys .
By pressing the key you can enter the input mode for the respective menu.
The input mode can be identified by a selected (shown reversed) line.
The keys can now be used to select the lines and the key used to change the value.
If a multi-digit numerical input is required, the highest digit is changed first.
You can use the key to proceed on to the next digit and so on.
If the input is a selection from several options (e.g., YES / NO), the required selection can be
reached using the arrow keys .
When the required option appears on the display, it can be confirmed using the key.

4.3 Main display
In the standard display, the control shows the switching status of the plant and the motors, e.g.:
1. line: Date and time
2. line: Current SBR cycle
2. line (right): Normal or eco-mode operation of plant, (remaining)
time that the current phase has left
3. line: Display of which motor is running or “motors off”, if all the
motors are turned off
4. line: Operating current of the motors
5. line: Error display
6. line: Floater status up or down
If the key is pressed, the following appears:
- Version
- Date of version
- Type (set PT)
- Effluent class
The key can also be used to turn off the buzzer in this menu (see also 5.4.6)
8
4.2 Commissioning
When commissioning the unit, the following information must be entered first:
- Password
- Language (see menu item 5.4.4)
- Date and time (see menu item 5.4.1)
- Plant size (see menu item 5.3.3)
- Denitrification (see menu item 5.5.2)
- PO -elimination (only for type K-Pilot 8.4, see menu item 5.3.4)
3
- Test mode - lasts approx. 1 minute (see menu item 5.3.1)
Following the test mode, a window appears with the prompt input ok?. This can be answered with
YES / NO. If the input is NO, you start again by entering the password, if YES, the standard
display is shown.
The commissioning engineer must ensure that the parameters are set in such a
way that they comply with any requirements from the construction approval for
the plant on which the control is intended to be employed.
4 Function

Denitrification menu is only
visible with denitrification is
activated!
5.1 Menu structure
9
5 Menu

5 Menu
The exact display is dependent on the plant´s status and the set parameters.
The different display versions are described in more detail below.
5.2 Runtime display
The menu item “runtime” displays the runtimes of the respective
motors. The runtimes are counted when the control has turned
on the aerator or the pumps.
The display shows hours and minutes.
The runtimes of the last (up to 52) weeks can be viewed by
pressing the key (operations diary).
The last line shows the date of the week (e.g., CW 52) in which
the values were saved (always Sunday).
The keys can be used to change from week to week.
Note:
This function only works correctly if the date and time have been
set correctly.
The runtimes of the dosing pump are only shown when
phosphate elimination is active.
5.3 Service menu
The service menu is basically intended for the service technician.
The following are typically selected:
- Change password (only with special password)
- System test / test mode
- Manual mode
- Clear counter (only with special password)
- Select plant size
5.3.1 System test / test mode
The automatic test mode is selected via the selection menu
“start test”.
The test mode checks whether the motors accept current properly.
In addition, the float switch is raised to test the function of the
float switch.
The main display changes during test mode.
10

5 Menu
11
System test process
1. Aerator 10 s
2. Filling pump 10 s
3. Clear water pump 10 s
4. If the float switch is down, wait until float switch changes position
5. Aerator until float switch changes ist position once again
6. System END
5.3.2 Manual mode
In manual mode each motor can be turned on an off manually
(e.g.,for a test). In addition, you can check the power consumption
of the motors switched on.
The keys are used to select the motor and the key is
used to turn the motor on and off.
For the clear water pump there is the additional option of the auto mode. In this mode, the pump
only runs when the float switch is up. Manual mode is ended via the menu item “end manual mode”.
Once manual mode has ended, the clear cycle continues.
5.3.3 Select plant size
In this menu you can set the plant size.
Select the menu item “SELECT PLANT SIZE” and press the
Key. The keys are used to select the appropriate plant
size with the PT no.
All the parameters for the cleaning process are then automatically
present.
The following function prompts then appear:
Denitrification:
The current denitrification setting (YES / NO) is shown in the first
line. The second line gives you the possibility to change this setting.
By pressing the keys you can select YES or NO for the
denitrification. The key is used to adopt the selected setting.
5.3.4 Phosphate elimination
Phosphate elimination:
The dosing pump can be activated on the K-Pilot 8.4.
(Activation like denitrification)

5.4 Basic settings
The operator settings are configured in this menu.
5.4.1 Setting the date and time
Example: Changing the date from 04.03.00 to 14.03.00 and the time from 07:53 to 07:54 o´clock.
The clock is quartz-controlled. It must also be checked as part of maintenance.
5.4.2 Alarm buzzer
The alarm buzzer can be turned off.
The acoustic alarm can be turned off for example from
18.00 to 06.00 o´clock.
Caution:
No alarm will sound during the set time period!
5.4.3 Display errors
This menu is used to call up the error log book.
The error log book displays the last 20 errors with the date and time.
The arrow keys are used to bwowse in the log book,
the middle key is used to exit the menu.
(Nothing can be deleted in the error log book)
5.4.4 Language
This is where the control language can be selected. It is necessary to enter the password for this.
There are a number of languages available for the control.
The languages currently programmed are:
- English - Finnish - German - Polish - Swedish
5 Menu
12

5.4.5 LCD contrast
The LCD contrast can be optimised here. A change is not normally necessary.
5.4.6 Clear alarm
If a malfunction occurs (alarm), this can be reset by pressing
the key on “NO ERRORS”.
Nevertheless, the error remains saved in the error log book.
The display shows OK for approx. 1 second and then returns
to the menu display.
Note: If the key is pressed once in the main display (standard display during operation) in the
event of a malfunction, the buzzer is provisionally turned off.
The error message is saved in the error log book and remains in the main display until it is
deleted with “CLEAR ALARMS”.
5.5 System menus for individual settings
The following menus are used to set all the plants´parameters individually.
These may only be adjustment by qualified specialists an in certain
circumstances they may reduce the cleaning capacity of the plant and void the
technical approval.
However, first of all a special password must be entered for you to be able to change the values.
It is not normally necessary to adjust the parameters as these are automatically present when you
select the PT no. (under “SELECT PLANT SIZE”).
To reset the original default settings, the plant size must be reselected again. (see menu item 5.3.3)
5.5.1 Aeration
This menu is used to set for how many minutes the aerator
should be turned ON or OFF (cycle).
This is specified for both normal operation and ecomode.
5.5.2 Denitrification
This menu is used to set for how many minutes the aerator should
be turned ON or OFF. This is done for both normal operation and
ecomode, but only for denitrification.
In addition, the duration of the denitrification is also set.
Note:
This menu is only visible when denitrification is activated.
5 Menu
13

5.5.3 Parameters
In this menu you can set the following parameters:
- Filling
- Sludge return
- Sludge return in x days
- Sedimentation
- Clear water flush
5.5.4 Current monitor
When the control turns on the aerator or a pump, there is no
guarantee that it will run. Overheating, defective cables or other
defects can mean that the switch relay is turned on but the motor
still doesn´t run. For this reason, the control monitors whether
Tthe current is flowing in the switching circuit.
If the current exceeds a limit, which is set at 0.2 A on the software side, a current alarm is emitted.
This menu is used to turn the current monitor ON or OFF.
This function can be turned on or off for each motor.
In addition, the current value for monitoring is displayed in the main display and manual mode.
5 Menu
14
6 Malfunctions / Alarm
1. HW High water: After clear water outflow, the float switch is not down
2. Battery Battery empty, defective or not inserted
3. Time Time not set
4. I Aer Aerator current error
5. I Fill Filling pump current error
6. I Clear Clear water outflow pump current error
7. Aerator
stopped
If a current error is identified three times by the aerator, while the aerator continues to
run in the meantime, it will be stopped to be protected from beeings destroid
8. Fuse?If a current error is registered for all three outputs, the fuse is probably defective
9. MAINS ON Mains is turned on
10. MAINS OFF Mains is turned off
11. Power
failure
Power failure < 1 min, the SBR cycle is continued
Power failure > 1 min, the SBR cycle is restarted
The following malfunctions can be displayed in the display :
Malfunctions are displayed by the flashing of the red operating LED.
The error message in the display once disappears once the error has been
resolved and cleared in the control. (see menu entries 5.4.3 u. 5.4.6)

The control has a power failure alarm.
In the case of a power failure, the alarm is given every 30 seconds to alert the operator to the
lacking treatment function. A crossed-out plug is shown in the display.
If the key is held depressed, an acknowledgement sounds and the alarm is turned off
permanently. If the energy supply is reconnected after the power failure, the device turns itself
back on automatically.
Note: For a new device, the internal batteries only reach their full capacity
to be able to attain a maximum alarm duration after a few days.
If the function of the internal batteries decreases, these must be replaced
with 2 NiMH - AA batteries.
They may only be replaced by a qualified electrician.
Unplug the device before opening it.
The batteries must be disposed of properly.
According to the German Battery Directive (BGBI 1998/I/20 from 2.4.98), since
1.10.98 all end customers of batteries are required to return these to the trader /
body responsible for the disposal of recyclable materials e.g., communal coll.
points. It is expressly forbidden to dispose of batteries in household waste.
7 Power failure alarm
The control is intended for assembly on a wall.
Connect the motors by means of the 7-pole plug.
Only then connect the mains plug!
After the control´s test mode, approximately 3 sec. later the text with the start message will appear.
Vx.xx (e.g. V0.04) is the software version no. A few seconds later, the standard display appears.
The green LED is illuminated continuously if a motor is on.
In the event of a malfunction / error, the red LED flashes.
If necessary, you can now adjust the parameters to suit your requirements (see menu item 4.2)
and return the main menu. The device is now ready for use.
The cables to the devices must be laid properly. In particular, special attention should be paid to
avoid heavy mechanical loads on the cables, e. g., through insufficiently fixed cables, as the
protection class IP 54 can otherwise not be guaranteed.
The 7-pole plug must be fastened correctly.
8 Assembly instructions
15

Temperature range (operation) 0°C … +40 °C
Temperature range (storage) -20°C … +70 °C
Air humidity (operation and storage) 0 … 90 % RH,non-condensing
Protection class Protective insulated
Type of protection IP 54
Dimensions (without cable connections, plug) approx. 200 x 120 x 60 mm
Assembly Wall assembly via screws
Housing material Light grey plastic
Mains connection (L1, N, PE) cable approx. 1,5 m long
with extruded shock-proof plug
230 V~ 50 Hz ±10 %
Motors (pumps / aerator)
Max. capacity(with fuse 3.15 A)
230 V/ 50 Hz,
P < 0.7KVA
Internal fuse (max 1.5W) 1 x 3.15 AT,max. 6.3 AT
Protection of pumps against overheating Via thermocontact in motor in row with
motor
Monitoring of current via a transformer
max 10 A,Type10% full power(10 A)
Power consumption control device Type5 VA
Float switch input (switches against N) Control voltage 230 V~ I < 10 mA
Requisite pre-fuse (s) max. 1 x 16 A G
Connection to treatment plant 7-pole and 4-poleplug for motors /
float switch
Cable diameter 1.5mm2(with ferrule)
Alarm relay max. contact voltage
max. contact
230 V~
8A; AC1
Internal buzzer Type 70 dB(A)
Displays Graphic LCD display 128 x64 mm
1 x LED green
1 x LED red
9 Technical data
16
10 Default settings
Population total (PT): 8
Denitrification: NO
- eliminiation: NOPo3

If it proves impossible to reinstate the seamless running of the clarificationplant, please
Contact our customer service department.
Always unplug before working on pumps and aerator!
Population total Fillling (sec) Normal aerator ON (min) Normal aerator OFF (min) Duration normal (min) Eco-mode aerator ON (min) Eco-mode aerator OFF (min) Duration eco-mode (min) Denitrif. normal aerator ON (sec) Denitrif. normal aerator OFF (min) Denitrif. duration normal (min) Denitrif. eco-mode aerator ON (sec) Denitrif. eco-mode aerator OFF (min) Denitrif. duration eco-mode (min) Mud flush (sec) Sedimentation (min) Clear water (min)
4 7 3,0 13,0 180 2,0 13,0 120 45,0 45 45,0 45 290 20
875,0 13,0 180 3,0 13,0 120 45,0 45 45,0 45 490 30
12 77,0 13,0 180 5,0 13,0 120 45,0 45 45,0 45 690 40
16 78,0 13,0 180 6,0 13,0 120 45,0 45 45,0 45 890 70
20 30 7,0 13,0 180 3,0 13,0 120 65,0 45 65,0 45 10 90 70
24 30 8,0 13,0 180 4,0 13,0 120 65,0 45 65,0 45 12 90 70
28 30 9,0 13,0 180 4,0 13,0 120 65,0 45 65,0 45 14 90 70
32 30 11,0 13,0 180 5,0 13,0 120 65,0 45 65,0 45 16 90 70
36 30 13,0 13,0 180 6,0 13,0 120 65,0 45 65,0 45 18 90 80
40 30 14,0 13,0 180 7,0 13,0 120 65,0 45 65,0 45 20 90 85
44 30 15,0 13,0 180 7,0 13,0 120 65,0 45 65,0 45 22 90 90
48 30 17,0 13,0 180 8,0 13,0 120 65,0 45 65,0 45 24 90 95
53 30 19,0 13,0 180 9,0 13,0 120 65,0 45 65,0 45 24 90 95
12 Error messages
17
11 Switching times
Display Possible cause Remedy
I Aer
The aerator pump has not
drawn the current
-Aerator pump defective
-Fuse defective
-Replace aerator
-Replace fuse
I Fill
The filling pump has not
drawn the current
-Filling pump defective
-Fuse defective
-Replace filling pump
-Replace fuse
I Clear
The clear water pump has not
drawn the current
-Clear water pump defective
-Fuse defective
-Replace clear water pump
-Replace fuse
HW
High water
-Ingress of other water
-Backwater receiving water
-Power failure
-Float switch defective
-Clear water pump blocked
-Clear water tube defective
-Localise ingress and block
-Possible one-off
-Ensure permanent energy
supply
-Replace float switch
-Remove blockage
-Replace clear water tube
Battery -Battery emty, defective or not
inserted
-Insert new battery
Time -Time not set -Set time
Aerator stopped? -Aerator is turned off after third
current error for protective reasons
-Check current supply
-Check aerator for blockage
Fuse?-Current error at all outputs -Replace fuse

13 Notes
18

19
This is to certify the compliance with the EC Directive for CE marking.
Device type: AQUATO
Electronic control device for automatic operation of fully
biological small wastewater treatment plant in accordance
with DIN 4261-2
Directives: EMC Directive 2004 / 108 / EEC
Low voltage directive 2006 / 95 / EEC
Applied standards: EN 61000 - 6 - 3 (2001)
EN 61000 - 6 - 1 (2001)
EN 61000 - 3 - 2 (1995)
EN 60204 - 1 (1997)
Manufacturer: AQUATO
umwelttechnologien GmbH
Borriesstraße 10
32051 Herford
R
R
13 Notes
14 Manufacturer certification
Ernstmeierstr. 24
32052 Herford

AQUATO
umwelttechnologien GmbH
Borriesstraße 10
32051 Herford
Germany
Tel.: + 49 (0) 5221-10 219 - 0
Fax: + 49 (0) 5221-10 219 - 20
E-mail: [e-mail]
www.aquato.de
Address
Ernstmeierstr. 24
32052 Herford